Method and apparatus for producing loose-leaf reinforced sheets



Feb. 1, 1966 R. H. DRIES ETAL 3,232,808

METHOD AND APPARATUS FOR PRODUCING LOOSE-LEAF REINFORCED SHEETS Filed Aug. 16, 1962 5 Sheets-Sheet 1 I NVENTORS ROBERT H. DRIES 8 Y JOSEPH J. LOUDA M ww gg ATTORNEYS Feb. 1, 1966 R. H. DRIES ETAL 3,232,803

METHOD AND APPARATUS FOR PRODUCING LOOSE-"LEAF REINFORCED SHEETS Filed Aug. 16, 1962 5 Sheets-Sheet 2 INVENTORS ROBERT H. DRIES a BY JOSEPH J. LOUDA ATTORN EYS Feb. 1, 1966 R. H. DRI ET AL 3,232,808

METHO ND AP PARA R PROD NG L0 LEAF REINFO D SHEE Filed Aug. 16, 1962 5 Sheets-Sheet 5 I NVENTORS ROBERT H. DRIES 8 BY JOSEPH J. LOUDA ATTORNEYS Feb. 1, 1966 R. H. DRIES ETAL METHOD AND APPARATUS FOR PRODUCING LOOSE-LEAF REINFORCED SHEETS 5 Sheets-Sheet 4 Filed Aug. 16, 1962 FIG-6 M HOa so 4 INVENTORS Feb. 1, 1966 R l s ETAL 3,232,808

METHOD ANi) APPARATUS FOR PRODUCING LOOSE-LEAF REINFORCED SHEETS Filed Aug. 16, 1962 Sheets-Sheet 5 I; FIG 12 IGQ 94 9 &

INVENTORS ROBERT H. DRIES 8s BY JOSEPH J. LOUDA ATTOR N EYS United States Patent 3,232,808 METHOD AND APPARATUS FOR PRGDUCING LOOSE-LEAF REINFORCED SHEETS Robert H. Dries and Joseph J. Louda, Dayton, Ohio, as-

signors, by mesne assignments, to Western Tablet 8: Stationery Corporation, Dayton, Ohio, a corporation of Delaware Filed Aug. 16, 1962, Ser. No. 217,439 8 Claims. (Cl. 156253) This invention relates to a novel method and novel apparatus for producing loose-leaf sheets of the type having holes punched in a predetermined pattern along an edge or margin of the sheet, in which such holes are reinforced to insure long life of the sheets when engaged with a looseleaf binder, particularly by avoidance of tearing the edge of the sheets engaged with the binder rings or similar apparatus.

The present invention is particularly directed to the so-called converting operation in which loose-leaf sheets, for example in the form of individual sheets as supplied in packets or packages, are provided from a relatively large and continuous web of sheet material, such as paper, which is supplied initially in a large roll. Broadly, the method and apparatus of this invention relate to the subdivision of this long web or roll of sheet material into individual sheets, a predetermined margin of which has been punched or formed with holes in a certain pattern for the purpose of engaging the rings of a loose-leaf binder or similar apparatus. Such sheets are particularly well known to be used by school children, although of course they are by no means limited to this particular use.

According to the invention a relatively large roll of sheet material, in the illustrated example a roll of paper, is unreeled and guided along a predetermined path in the form of a web, of single thickness, drawn from the roll and driven at relatively high linear speed. At predetermined areas on the web a patch of reinforcing material, preferably though not necessarily heat scalable, is placed upon the web and is adhered thereto to form a lamination or reinforced area which is subsequently punched or similarly formed with a hole, such areas subsequently becoming a predetermined margin of sheets which are cut from the traveling web.

Thus, the primary object of this invention is to provide a novel apparatus by means of which reinforced loose-leaf sheets, of paper or like material, are formed from a relatively long web of the material.

. Another important object of this invention is to provide a novel method by means of which reinforced loose-leaf sheets are formed from a large web of sheet material.

. Another important object of this invention is to provide a novel loose-leaf sheet, for example of the type which is supplied in packets or pads of sheets of this type, and in which the holes or perforations formed to engage the loose-leaf binder apparatus are reinforced to enhance the resistance of the loose-leaf sheets to tearing from the binder apparatus, and in which such reinforcement is limited to the immediate area of the holes or perforations in the individual sheets.

Another object of the invention is to provide novel apparatus for the aforestated purpose, in which the patching or reinforcing laminate material is supplied in the form of a continuous, or substantially lengthy, strip of material of a width corresponding to the width of the desired patch, together with apparatus for cutting such material into patches of the desired size for reinforcement, in combination with applicator apparatus which removes such patches from the supply of reinforcing material and applies the patches to a moving web of paper or the like at essentially the same speed at which the web is driven, and, in the ICC case of heat scalable patches, apparatus for retaining the patches upon the web in the exact position at which they are placed while heat sealing of the reinforcing patches to the web is effected.

Another important object of this invention is to provide novel apparatus for applying reinforcing patches to the area of the holes of loose-leaf paper sheets, in which the patches are applied to areas of a continuously moving web of sheet material which are predetermined to become the areas where the holes or perforations are formed in one margin of the sheets to be cut from the web, and in which such patches are securely and permanently fastened, as by passing through nip rolls, so as to become effectively a thin reinforcing laminate which reduces the tendency of the sheet material to tear when binder apparatus is engaged with the holes formed through the reinforced patches.

Other objects and advantages of the invention will be apparent from the following description, the accompanying drawings and the appended claims.

In the drawing:

FIG. 1 is a view of a typical reinforced loose-leaf sheet which is the end product of the present invention;

FIG. 2 is a perspective View, diagrammatic in form,

which shows the overall arrangement of apparatus in ac:

cordance with the invention;

FIG. 2A is a view similar to FIG. 2, showing the manner in which the apparatus can be combined with conventional ruling and sheeting devices;

FIG. 3 is a side elevational view, on a somewhat larger scale than FIG. 2, showing the essential parts of the apparatus and the drive therefor;

FIG. 4 is a plan view of the segment of the web rial, showing a typical manner in which reinforcing patches are applied to the moving web, and showing in dotted outline the ultimate sheet form into which the Web is cut to produce the loose-leaf sheet product;

FIG. 5 is a side View on an enlarged scale, partly in section, showing details of the patch applicator, vacuum retainer, and heat sealing apparatus in accordance with the invention;

FIG. 6 is a sectional view taken generally through the entrance end of the apparatus, as viewed from the left of FIG. 5, and illustrating the feed reels for the reinforcing material to show a typical multiple arrangement thereof, as well as showing the manifolding for the vacuum connections to the apparatus and a preferred arrangement whereby two webs of sheet material are patched and subsequently formed into loose-leaf sheets simultaneously;

FIG. 7 is an enlarged and broken view, with a portion shown in section, of the feeder mechanism for the strips of reinforcing material;

. FIG. 8 is an enlarged end view of one of the guide.

structures for the reinforcing strips;

FIG. 9 is an enlarged sectional view of one of the gripper heads on the applicator drum, showing also details of the cut-off knife which cooperates with the gripper head to sever the patch from the strip of reinforcing material;

FIG. 10 is a detail sectional view, on an enlarged scale, showing a cross-section of a pair of the vacuum retainer mainifolds which act through the moving web to hold an applied patch properly in the position in which it is applied to the web during the heat sealing operation;

, FIG. 11 is a broken detail view, on a larger scale, showing a suitable arrangement of the face plate of the vacuum manifold retainer, which is also a part of the structure used to effect the heat sealing;

FIG. 12 is an enlarged detail view, with certain parts broken away and shown in section, illustrating the structure of a suitable applicator drum with gripper heads thereon;

mate- FIG. 13 is a sectional view taken through one end of the applicator drum, with a segment broken away and shown in section, illustrating the arrangement of gripper heads about the periphery of the drum;

FIGS. 14, 15 and 16 are views on essentially the same scale, with parts broken away and shown in section in FIGS. 15 and 16, illustrating details of the rotary valving mechanism by means of which a retaining or guiding vacuum is directed to surface portions of the applicator drum and a vacuum for gripper purposes is directed cyclically to the gripper heads; and

FIG. 17 is a detailed sectional view of the vacuum retainer structure which extends about the applicator drum from one gripper head to the next.

Referring to the drawings, and particularly to FIG. 1, this figure shows a typical loose-leaf sheet it) which is the ultimate product of the present invention. For purposes of illustration the sheet is shown as having five holes or perforations 12 formed therein, whereby the sheet will be accommodated in standard two-ring or standard three-ring loose-leaf binders. It should be understood, however, that the present invention is not limited to this particular type of sheet, but can be a plied with equal facility to the manufacture of sheet suitable only for two-ring or for three-ring binder use, and also to sheets wherein the binder holes are at some other edge part of the sheet than the side shown. However, as a typical example the sheet shown in FIG. 1 is universally applicable to a wide variety of loose-leaf binders. The outermost holes, designated 12a and 1212, would be those engaged with the upper and lower retainer rings of a three-ring binder, and these holes are provided with reinforcing patches 15 in accordance with the invention, it being unnecessary and often undesirable to reinforce the center hole for this purpose. Since the sheet is also applicable to tworing binders, the inner pair of holes 12c and 12d are also provided with patches 15, these being the holes which would be operative when the sheet was placed in a standard two-ring binder.

In accordance with the invention the normal loose-leaf sheet is reinforced by application or lamination of the reinforcing patches to the above described holes only. Thus, the invention effects a considerable economy of product, since the relatively expensive reinforcing material, for example transparent plastic such as a commercially known Mylar film or its equivalent, is relatively expensive in comparison to the paper or like material from which the sheets are normally formed. It should also be noted that the sheet lift is illustrated, for purposes of example, as a plain or unruled sheet. The present invention, however, is also fully applicable to ruled sheets as well, as will be apparent from the following description.

Thus, referring to FIG. 2 and FIG. 2A the sheet material, preferably or usually in the form of a roll 20 of paper, is unreeled over a plurality of guide rolls 22 and directed to a turning bar 23 over which the web is threaded and passed about the entry guide bars 24 of the apparatus provided by this invention. It should be understood that conventional drives for rotating the roll 20, to overcome for example the inertia of the roll and to assure proper unrolling thereof, may be provided by any suitable conventional drive mechanism. From the guide bars 24 the web is passed to an applicator station, indicated by a general reference numeral 25. It is at this station that the patches of reinforcing material are placed in predetermined proper position upon the traveling web 30, which is being unrolled, under drive, from the roll 20. Details of the applicator device are described hereafter.

Immediately following the applicator section, the web passes through a sealer section, indicated by the general reference numeral 32, and from this section the web is threaded about a pair of guide bars or rolls 33 to extend between the entrance guide rolls 34 of a punching or hole forming mechanism, shown in its preferred embodiment as a rotary punch designated by the general reference numeral 35. From the punching or hole forming section, the web may pass into a ruling apparatus 38 of conven-' tional design and the details of which form no particular part of the present invention. It should be mentioned, however, that the drive for the ruling mechanism 38 is correlated to the drive for the remainder of the apparatus, as will be noted. It is also possible to rewind the web at this point and to pass the patched and perforated web through conventional ruling and/or sheeting apparatus at a dilferent location.

From the ruling apparatus 38 the web 36 passes to cutter or sheeting mechanism including a slitter 40 and a rotary cutter 42, which serve to sever the web 30 into a plurality of individual sheets, the resultant being the end product loose-leaf sheets which include the reinforced perforations or holes in the predetermined areas along one edge of the sheets.

It will be noted, particularly from FIGS. 2 and 3 of the drawing, that the present invention contemplates proceasing of two webs of paper or other sheet material simultaneously. Thus, the other or upper web 30a is fed into duplicate applicator apparatus at the station 25a over a guide roll or bar 24a. The web 30a then passes through sealer section 32a and over exit guide rollers 33a to meet with the web 30 in the area between the guide rollers 34. The two webs then move together, in contact, and the timing of the applicator apparatus 25a is directly related to the applicator mechanism 25 such that the patches on the web 39a will overlie directly the patches on the web 30. The two webs are moved together through the hole forming mechanism or punch 35, after which the webs can be separated for rewinding, as mentioned, or to pass through the ruling apparatus 38, and they can be again joined in the cutter mechanism where the webs are simu1- taneously divided into the individual loose-leaf sheets.

Thus, except for certain showings as in FIG. 3 to relate the arrangement of the upper and lower applicator and sealer mechanisms, it will be assumed that details of these two mechanisms are the same, and the detailed description is hereafter concerned with the details of the lower applicator and sealer mechanism only.

The general operation of the applicator means is as follows. A continuous film or the like, preferably a heat scalable material, for example a transparent film-like material known commercially as Mylar, is supplied in relatively long large rolls which are in turn mounted in suitable reels 50. There is one reel for each patch to be applied to a sheet, and in a preferred embodiment of the invention a web 30 is of sufiicient width to form two sheets therefrom. Accordingly, as shown in FIG. 6, there are eight such reels 50 mounted so as to be freely rotata ble about suitable axles 52, which are shown both in FIG. 6 and in FIG. 5. The film, designated by the general reference numeral 55, is threaded from each reel 50 over a stationary guide rod 56, and thence over a feeder control or drive mechanism being provided for the purpose of unreeling the film 56 at a predetermined uniform speed. The unreeling mechanism includes the following members.

A stationary elongated cylinder member 60 (FIG. 7) is mounted across the path of travel of the web 30, and considerably above the web as shown particularly in FIG. 5. In the portions of this cylinder member where the films are to pass over, there are slots 62 which are of a width corresponding to the width of the film. In FIG. 7, an area is shown wherein the slot 62 is a little more than twice the width of a film 55, since this corresponds to an area where two films from adjacent reels 5% (FIG. 6) are passed over the feeder mechanism. Within the cylinder 66 there is a rotary feed cylinder 65, and in the areas where the film is to engage the cylinder there are a number of circumferential slots 66 which are connected through radially directed holes or passages 67 to the interior of the rotating member 65. liVithin this member, providing a stationary support and also a corn venient direct source of vacuum, there is a stationary mounted bar or rod 70, preferably having the appearance in cross section as shown in FIG. 5.

This bar is of generally squareccross-sectional configuration having the corners thereof rounded oif according to the inner diameter of the cylinder 65. A central vacuum supply passage 72 extends through the bar member 70, and is connected to a suitable source of vacuum (de scribed further on) which in turn is transmitted through the outward extending passage 73 to the interior of the cylinder 65, from whence the vacuum is applied through the passages or holes 67 to the slots 66 on the feeding cylinder. In this manner, since the circumferential guide slots 62 are provided with flat end faces 74, the film 55 extends over these faces and provides a running seal with the passages 66 whereby the vacuum is exerted directly on the film 55 and the rotating cylinder 65 is caused to feed the film forward at the predetermined speed of rotation of the cylinder.

From this feeding mechanism each film extends to a forward guide apparatus provided by a pair of side plates 76 mounted on a hub 77. This hub in turn is supported on across rod 78, and each hub carries a normally stationary guide rod or stub 80 over which the film 55 is threaded. From this guiding apparatus the film is passed forward to the applicator means, which includes as part of its mechanism the rotating applicator drum 85. This drum is driven, in the direction shown by the arrow. in FIG. 5, at a rate such that its peripheral speed corresponds to the linear speed of the moving driven web 30. Thus, as patches of the reinforcing material are severed and guided onto the moving web 39, the speed at which the patches are applied will be essentially the same as the speed of the moving web, there being practically no relative velocity therebetween, and thus essentially no relative movement between the patches and the web.

The applicator mechanism, as noted, includes the drum 3.5, and in this drum there are a plurality of gripper means or members, preferably in the form of vacuum gripper heads. Details of one such head are shown in FIG. 9, while other portions of this head are shown also in FIG. 13. The gripper heads are designated by the general reference numeral 90. Each of them includes the body or block 92 having a plurality of vacuum gripper passages 93 extending transversely through the block, and opening on the, inner face of the block into a vacuum passage 94 which extends transversely, or (as viewed) along the drum 85, with such passages being connected through suitable valving to the vacuum source. Details of the valving are explained further on.

The gripper block 92 is formed of relatively hard mate rial,, such as hardened steel, since it serves also as a backup plate or die plate against which the cutoff knife 95 actsto sever patches from the moving film 55. The knife is mounted in a rotary cutolf drum 96 which, as shown in FIG. 5, is driven in the opposite direction from applicator drum 8-5, and of course at the same speed. Preferably there are two such cutoff knife members 95, at opposite sides of the drum 96. Each includes the replaceable blade 95 and a clamping block 97 which is urged against the knife blade by an adjusting bolt 98. Other equivalent cut-off means can also be used, such as a heated wire contacting the film at appropriate intervals.

, As the knife blade engages the gripper body or block 92 it functions to sever a patch 1% (FIG. 9) from the film 55. It will be understood that this is one of the patches shown in FIG. 1 applied as a reinforcement patch to the loose-leaf sheet 10. At this point passage 94 is connected to the vacuum source, in a manner to be explained, and thus the patch 100 is held on the vacuum gripper head 90. As the knife blade is carried away from the gripper head block 92, it may under some circumstances tend to carry the trailing edge of the patch 100 with it, and to avoid this and assure that the patch remains properly against the vacuum gripper head, a stripper wire 105 (FIG. 9) extends between the applicator drum and the cutofi drum 96, immediately beyond the nip therebetween.

The leading or forward edge of the patch is held against block 92, and it passes underneath. the wire 105.

If the trailing edge of the now severed patch tends to follow the knife 95, the wire will hold the patchaway from the knife and assure that it remains properly on the gripper. The remainder of the film 55, being constrained to move at a considerably lesser speed than the peripheral speed of the drums, will lag behind, and thusthe gripper head will carry the severed patch away from the film and apply the patch to a predetermined area of includes a frame provided with a number of elon gated cavities 112 corresponding to the number of patches to be applied across the web. Each of these cavities is provided with a removable cover plate 115, preferably of thin rigid metal such as brass which has good heat transmission characteristics but will retain its fiat configuration. Within the cavities there are mounted infrared quartz heating elements 117, carried on a plurality of.

insulator mountings 118, and connected to a suitable energizing source of electricity v(not shown) through the connectors 119.

The cavities 112 are in turn connected through a suitable fitting 120 to a vacuum source, and the cover plates.

are provided with a series of relatively small holes 122 (FIGS. 10 and 11) which connect the upper surface of these plates over which the web .30 is guided to the lower pressure section in the cavities. A retaining vacuum is thus exerted on and through the traveling Web 30' tending to hold the patches 100 in the position where they were applied to the traveling web while heat radiates through the web and serves to heat seal the patches to the opposite or upper surfaces of the web 30 as viewed in FIG. 5. In some instances, heating may be accomplished from above the Web, as by radiation directly onto the web and the patches thereon, but with the ,Mylar film described heating from below is preferred.

In a preferred emobdiment of the cover plates 115,

there are individual tracks or paths of the holes 122, the holes being greater in number in the end of the lates toward the applicator drum, and decreasing in number along the direction of travel of the web. Also, the holes may be staggered along thesepaths in a ziz-zag configuration, as shown in FIG. 11, to induce a straightening of squaring action on the patches in the event that the patches might not be precisely aligned on the web when released by the applicator mechanism. This configura,

tion is not an essential feature, as the apparatus has been found to function with complete satisfaction without this zig-zag pattern.

The web then passes between nip rolls 123 which press the patches against the web to assure a complete bond-- ing of the patches to the Web. A stream of cool air may be directed against these nip rolls to blow 011" any patches which might have been picked up by them. This cool air also serves to keep these nip rolls at a. considerably lower temperature than the patch and web so that a brief chilling effect on the patches is obtained. This chilling can also be obtained, or enhanced, by using fluid cooled hollow nip rolls.

This means for controlling the connection of the vacuum gripper heads 9t? is in the form of a rotary valve apparatus indicated in FIG. 12 by the general reference numeral 125. The side frame member 126 'of u the machine providesa mounting for the satisfactory,

or supply plate 128 of the valving mechanism, details of this plate also being shown in FIG. 16. It includes the vacuum supply passage 130 and a fitting shown generally at 132 by means of which a flexible hose coupling or the like can be connected thereto, such hose extending to a vacuum supply manifold (to be described later). As shown in FIGS. 12 and 16 the supply plate 128 is fitted with a bearing sleeve 133 which also provides support for the drive shaft 135 of the drum 85.

The supply plate 128 is fastened in any suitable manner to the side frame 126, and a bracket support bearing 137 ('FIGS. 15 and 16) is fastened to the plate 128 by a bolt 138. It should be noted that this bolt extends through an elongated slot 139 (FIG. 16) in the bracket 137, such that the bracket can be adjusted to some extend along the periphery of the stationary supply plate 128. The valving plate 1411, details of which are shown in FIG. 15, is carried by the bracket 137, being fixed thereto by a bolt 141. This plate 145), since it is stationary during normal operation, is provided with a central opening 142 which will fit over the shaft 135 and permit free rotation of the shaft therein. A vacuum supply and control slot 145 is formed about a substantial portion of the valving plate 144 such slot being formed on an are which is concentric with the central hole 142 (and thus with the shaft).

The slot 145' preferably extends over slightly less than 180, and it is always in communication with the vacuum supply passage 130 in the supply plate 128. Adjacent the bottom of the plate 144 there is a separate pressure air supply slot 147 connected by a passage 143 to an externally projecting fitting 149 which may be connected to a source of air under pressure. The slots 145 and 147 are formed on the same radius, and thus will serve to connect the gripper heads 90 first with a source of vacuum, and then to a source of air under pressure, in the desired sequence.

To perform this function, the drum 85 carries a rotary valving plate 150, details of which are shown in FIG. 14. This plate is fastened to the end of the drum 85 by one or more bolts 151. The end of the drum 85 which receives the plate 150 is shown in FIG. 13, and the face configuration of the plate 150 is shown in FIG. 14. Thus, the drum is formed with the four (preferably) longitudinal extending passageways or slots 94. Over these are mounted the gripper heads 91], as shown in FIGS. 12 and 13, and in the sections between gripper heads suitable covers 154 seal the passage. Each of the passages 94 terminates at the rotary valving plate 150 in communication with a corresponding vacuum supply slot 155, and these slots in turn will communicate with the stationary vacuum supply passage 145, and, later on during rotation of the plate 150 (counterclockwise as viewed in FIG. 14) with the pressure supply passage 147.

On opposite sides of each passage 94 in the drum 85 there are further vacuum supply passages formed, for example, as extended bores, all designated by the reference numeral 156. In the areas where the gripper heads 90 are located the drum 85 has a plurality of circumferential grooves 160 formed therein, details of these grooves being shown in FIG. 17. Each groove is provided with a connection to all the passages 156 through small connecting passages 162, and the passages 156 in turn lead at their ends into corresponding passages 164 in the rotary valving plate 150. These passages in turn connect with the vacuum supply slots 145 to form a connection directly between the supply passage 130 on plate 128 and each of the grooves 160, constituting a vacuum holding arrangement over a substantial extent of the slots 160. The film 55 extends over these slots, particularly as shown in FIGS. and 9, and a sliding vacuum arrangement obtains which holds the film in contact with the drum 85 and in proper alignment thereon for subsequent pickup by one of the heads 90.

Thus, there will be an arrangement of slots 160 and corresponding pickup heads 91 for each of the film sup ply reels 5t), and the number of these arranged across the apparatus will vary according to the type of sheet end product desired. For example, if four holes are to be reinforced on each sheet, since the web ordinarily runs two sheets in width as shown in FIG. 4, then there will be eight such reels and pickup heads with attendant apparatus properly spaced across the machine, and eight patches will be placed on the moving web simultaneously, as shown in FIG. 4. Obviously, this number can be changed as desired.

Each film threads over the vacuum retainer or tensioning apparatus 58 and passes thence over the guide members 81 onto the surface of the rotating applier drum 85, the end of each film laying over (and part way around as shown in FIG. 5) a corresponding set of grooves 16%. The vacuum applied through these grooves tends to pull the film forward, but does permit slipping. On the other hand, the gripper heads 90, once a patch has been severed from the film 55, provide a positive gripping action on the patch, as previously described and as shown in FIG. 9, and thus the gripper head will carry the patch forward once it is severed, accelerating it with respect to the film 55 and applying the patch to the proper area of the moving web 30.

Essentially at this time the pressure air supply through slot 147 (FIG. 15 and plate 146) will be connected to that passage 94 of the gripper heads then carrying the patches, which have just contacted the web. A relatively short burst of air under pressure will thus be applied through the gripper heads to assure that the patches are released onto the moving web 30. The adjustment of bracket 137 on the stationary plate 128 provides for sufiicient circumferential adjusting movement of the stationary valving plate to attain the proper timing of this positive air pressure supply, and also to assure proper timing of the cutoff of the vacuum to the gripper heads, when the corresponding passage moves beyond the lower end of the vacuum supply slot 145.

The arrangement of conduits for supply of vacuum to the various parts of the apparatus is shown in FIG. 6. A suitable power driven vacuum pump, parts of which are shown at 170, has its inlet 17?. connected to a pair of vacuum manifold pipes 173 and 174. These are of like size, one extending to the bottom half of the apparatus and the other extending to the top. As in the previous description, only the bottom portion will be explained in detail, with the understanding that the top half is in all essential respects a duplicate of the bottom. Thus, the manifold pipe 174 connects into the bottom vacuum supply manifold 175, and it is provided with a plurality of nipples 177 which are connected through suitable conduit, such as flexible hose conduit shown schematically at 178, to the fittings 120. Further nipples 179 are connected by suitable flexible hose or the like (not shown) to the fitting 132. The supply of air under pressure can be obtained from any suitable source, and therefore no specific pump or the like for this purpose is shown, it being understood that whatever air pressure source is used will be connected to the fitting 149 for the purpose previously described.

In order to maintain synchronism of the units, the entire apparatus is driven from a common drive motor, shown schematically at 180 in FIG. 2. This motor is provided with drive shafts 182 and 183, shown schematically, to the line marking apparatus 38 and to the final cutter 42, respectively. Likewise, the motor drives a line shaft 185 which is connected through suitable gears 186 to drive the rotary punch 35, and which is also connected through bevel gearing 188 at its forward end to drive the drum 35 carrying the pickup heads. The cutoff knife drum is gear driven at the same speed as drum 85, by the gears 189, and the drive for the feed or supply roller 65 is provided by suitable pulleys providing the desired speed reduction, these pulleys being connected by timing :belts, and the entire speed reduction and feed drive unit being shown schematically at 190. In order to maintain synchronism of the upper and lower applicator devices, the upper drum 85a is driven through the timing belt drive 193, or its equivalent such as a chain and sprocket drive, and the upper tape feed or supply mechanism is in turn driven from the shaft of the upper drum 85a.

It will be seen from the foregoing description that the present invention provides a novel method and apparatus whereby the holes in individual loose-leaf sheets are reinforced as a part of the process of manufacturing such sheets. The sheets of course may be ruled or not, and may have the conventional retainer hole configurations of two, three, or five appropriately spaced holes, or any other desired pattern, in any predetermined margin or margins of the sheet. The applicator apparatus is capable of operating speeds at least equal to punching and ruling machines, and there thus is no need to slow down the operation of these devices for the purpose of applying the reinforcing patches. The patches are applied to the moving web and heat sealed or laminated thereto while the web is moving continuously at "high speed, for example at speeds in the order of 300 to 500 feet per minute. The usual size patch is a one-half inch square of transparent heat seala-ble material, such as a prestressed synthetic film known commercially as Mylar, of about 0.001 inch thickness.

The supply apparatus to the applicator drum operates at significantly slower speed, and the patches are cut from the moving film supply strip and accelerated to the speed of the moving web, such that when the patches are placed on the web there is essentially no speed differential between the patch and the web. Operating at these speeds, any increment or small section of the web material is in contact with the heated plates 115 for only a short period of time, approximately one and one-half to. two seconds, and thus these plates can be heated to a normal running temperature in the neighborhood of 420 to 430 F. to achieve proper heat sealing without danger of scorching the web. The heat is preferably applied through the web, i.e., from the side of the web opposite to the applicator mechanism, since this has been observed to prevent curling of Mylar patches and assures a good seal between each patch and the web. The patches are capable of cooling or setting rapidly, such that they are satisfactorily adhered to the web by the time they reach the rotary punching apparatus 35, and this apparatus can effectively punch the necessary holes through the patches and the web, without stripping the patches from the Web as the Web travels beyond the rotary punch.

Accordingly, the present invention provides a novel method and apparatus whereby loose-leaf sheets are effectively and economically reinforced using only that amount of reinforcing material necessary to reinforce the areas of the sheets around the retaining holes, and operating at such a rate that the application of the reinforcing patches is comparable to the normal operating speed of ruling and/ or punching apparatus.

While the method herein described, and the form of apparatus for carrying this method into effect, constitute preferred embodiments of the invention, it is to be understood that the invention is not limited to this precise method and form of apparatus, and that changes may be made in either without departing from the scope of the invention which is defined in the appended claims.

What is claimed is:

1. The method of manufacturing sheets of paper and the like having reinforced holes for engaging retainers in n loose-leaf binder, comprising the steps of (a) applying patches of thin reinforcing material to a moving web of paper at predetermined locations of holes in individual sheets to be formed from the web,

(b) holding the patches in their exact place on the web by a vacuum applied to the opposite side of the moving web from the side to which the patches are applied for an extended part of the path of travel of the web,

(0) heating the web during at least a substantial portion of said part of its travel path to bond the patches onto the web,

(d) forming holes through the combined patches and web, and

(e) separating the web into individual sheets.

2. In the manufacture of loose-leaf paper sheets having reinforced holes in the steps comprising,

(a) supplying paper to form the sheets in a continuous web guided along a predetermined path of travel,

(b) supplying at predetermined locations transversely of said web elongated strips of thin reinforcing material,

(c) severing reinforcing patches from said strips,

(d) laying said patches on the moving web spaced lengthwise of said web according to the desired size of sheets,

(e) holding the patches against the moving web in the precise position at which they were applied by creating a differential pressure on the patches tending to hold them in place on the moving web,

(f) adhering the patches to the moving web,

(g) forming holes in the web through all of said patches,

(h) and separating the web into sheets with the reinforcing holes along a margin thereof.

3. The method defined in claim 2, in which the reinforcing patches are formed of heat-scalable material, including the additional step of r (i) heating the heat-sealable patches by applying heat through the web for a substantial interval after they are laid on the moving web to bond the patches to the web.

4. Apparatus for converting a web of sheet material into loose-leaf sheets having reinforced holes for engaging with a binder apparatus, comprising means for guiding a web of the sheet material to move along a fixed path lengthwise of the web, drive means for moving a web along said path, means forming an applicator section on said path including applicator mechanism adapted to bring patches of reinforcing material into contact with the web at regularly spaced locations therealong, means providing a sealer section immediately beyond said applicator section means in the direction of travel. of said web, retainer means in said sealer section operative to maintain the patches in position on the web and to cause sealing of the patches to the moving web, and hole forming mechanism receiving the web passing from said sealer sections means and operating in timed relation to said applicator means to form holes through the patches and web of sheet material.

5. Apparatus for converting a web of sheet material into lose-leaf sheets having reinforced holes for engaging with a binder apparatus, comprising means for guiding a web of the sheet material to move along a fixed path lengthwise of the web, drive means for moving a web along said path, means forming an applicator section on said path including applicator mechanism adapted to bring patches of heat sealable material into contact with the web at regularly spaced locations therealong, means providing a sealer section immediately beyond said applicator section means in the direction of travel of said Web, transfer means in said sealer section operative to maintain the patches in their locations on the moving web, heater means operating to heat the web to cause heat sealing of the patches to the moving Web, and hole forming mechanism receiving the web passing from said sealer section and operating in timed relation to said drive means and to said applicator means to form holes through the patches and web of sheet material.

6. Apparatus for converting a web of sheet material into lose-leaf sheets having reinforced holes for engaging with a binder apparatus, comprising means for guiding a web of sheet material to move along a fixed path, drive means for moving a web continuously along said path at substantial speed, means forming an applictor section on said path including a rotary applicator drum having a plurality of gripper heads adapted to bring patches of heat scalable material into contact with the moving web at regularly spaced locations therealong, means providing a sealer section immediately beyond said applicator section means in the direction of travel of said web, vacuum retainer means in said sealer section means operative through said Web to maintain the patches in their locations on the Web, heater means extending adjacent said retainer means and operative to cause heat sealing of the patches to the moving web, hole forming mechanism receiving the web passing from said sealer section means and operating in timed relation to said drive means and to said applicator means to form holes through the patches and web of sheet material, and cutter mechanism receiving the web from said hole forming mechanism and operating to sever the web material into individual sheets with the reinforced holes at a predetermined margin of each such individual sheet.

'7. Apparatus for forming loose-leaf sheets having rein forced holes from a relatively long web of sheet material, comprising means for guiding a Web of such sheet material along a fixed path lengthwise thereof, drive means for moving a Web along said path, a rotary applicator drum driven at a peripheral speed equal to the speed of the moving Web and mounted across the path of travel of the web to contact the web, gripper means on said drum, means supplying patches of heat scalable reinforcing material to said gripper means in timed relation to movement thereof against the web, controls for said gripper means causing release of a patch onto the moving Web at substantially the same velocity as the moving web, a vacuum retainer manifold extending for a substantial distance lengthwise of said path from said applicator drum, means mounting said manifold on the opposite side of the moving web from said drum to exert a retaining vacuum through the web on patches placed on the web, a heater mounted to heat the parts of said manifold facing the web to transmit sufiicient heat into and through the moving web to adhere the seat sealable patches to the web, a rotary punch driven in timed relation to the web according to the spaced placement of the patches for punching a hole through each patch and 12 the area of the web where a patch is adhered thereto, and cutter mechanism receiving the web from said punch and operative to separate the web material into individual sheets With the reinforced holes at a predetermined margin of each such sheet.

8. Apparatus for forming ioose-leaf sheets having reinforced holes from a relatively long Web of sheet material, comprising means for guiding a Web of such sheet material along fixed path lengthwise thereof, drive means for moving a web along said path, a rotary applicator drum driven at a peripheral speed equal to the speed of the moving web and mounted next to the path of travel of the web, gripper means on said drum, means supplying a strip of heat scalable reinforcing material to the surface of said drum, a cutoff knife operating on said strip in timed relation to movement of said gripper means and the web to sever patches from said strip for carrying by said gripper means against the web, controls for said gripper means causing release of the patches onto the moving web, a vacuum retainer manifold extending for a substantial distance lengthwise of said path from said applicator drum and on the opposite side of the moving Web from said drum to exert a retaining vacuum through the moving Web on patches placed on the web, a heater mounted coextensive with said manifold heating the parts of said manifold facing the web to transmit sufficient heat into and through the moving web to adhere the heat scalable patches to the Web, and punch means driven in timed relation to the moving web according to the spaced placement of the patches for punching a hole through each patch and the area of the web where a patch is adhered thereto.

References (Iited by the Examiner UNITED STATES PATENTS 2,289,336 7/1942 Bamford 156519 2,291,841 8/1942 Staude l56-510 2,525,741 10/1950 Von Hofe et al. 156-571 XR 2,878,953 3/1959 Mitchell 156--571 XR 2,990,081 8/1961 Neui et al 156519 FOREIGN PATENTS 578,616 6/1958 Italy.

EARL M. BERGERT, Primary Examiner.

DOUGLAS J. DRUMMOND, Examiner. 

1. THE METHOD OF MANUFACTURING SHEETS OF PAPER AND THE LIKE HAVING REINFORCED HOLS FOR ENGAGING RETAINERS IN A LOOSE-LEAF BINDER, COMPRISING THE STEPS OF (A) APPLYING PATCHES OF THIN REINFORCING MATERIAL TO A MOVING WEB OF PAPER AT PREDETERMINED LOCATIONS OF HOLES IN INDIVIDUAL SHEETS TO BE FORMED FROM THE WEB, (B) HOLDING THE PATCHES IN THEIR EXACT PLACE ON THE WEB BY A VACUUM APPLIED TO THE OPPOSITE SIDE OF THE MOVING WEB FROMTHE SIDE TO WHICH THE PATCHES ARE APPLIED FOR AN EXTENDED PART OF THE PATH OF TRAVEL OF THE WEB, (C) HEATING THE WEB DURING AT LEAST A SUBSTANTIAL PORTION OF SAID PART OF ITS TRAVEL PATH TO BOND THE PATCHES ONTO THE WEB, (D) FORMING HOLES THROUGH THE COMBINED PATCHES AND WEB, AND (E) SEPARATING THE WEB INTO INDIVIDUAL SHEETS. 